Dimensionally Stable Floor Panel

ABSTRACT

A floor panel is provided. The floor panel composition includes a wear layer and a base layer. The base layer includes a first base sections having a first composition of polyvinyl chloride, filler, and plasticizer, a second base sections having a second composition with a higher content of polyvinyl and plasticizer than the first composition, and a glass fiber section positioned between the first base section and the second base section.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of the filing date under 35 U.S.C. §119(a)-(d) of U.S. Provisional Patent Application No. 62/408,998, filedOct. 17, 2016.

FIELD OF THE INVENTION

The invention generally relates to a floor panel and, more specifically,to a dimensionally stable floor panel composition having a reinforcedlayer with a guide edge

BACKGROUND

Luxury vinyl tiles (“LVT”) are generally well known and a considerablypopular flooring option. LVT can be manufactured to have a natural lookof wood, stone, slate, brick, ceramic or many other designs as long asthey can be printed on a film by rotogravure printing, digital printingand many other means. The flooring is designed with the resilience anddurability of hard-wearing vinyl flooring. While adhesives and lockingsystems are commonly used during the installation of LVT, loose layfloating installation has become much more popular, considering thesimplicity and efficiency during installation.

A loose lay tile (“LLT”) product is simply laid freely on the floor orsubfloor and installed snugly tight against the walls. LLTcharacteristically require a few critical features: (1) a lowcoefficient of expansion and contraction, (2) thick and heavy with glassfiber veil to give the best dimension stability and fixation ofplacement, (3) flatness to make the visual of a large installation floorlike a monolithic flooring sheet, and (4) a non-slip backing to furtherimprove its fixation of its placement. However, even with excellentflatness properties, deformation often results from inadvertent mistakesduring packaging and storage. Edge peaking and curl problems usuallyoccur and are accentuated even more during the transportation,particularly in cold climates. These issues are not only visuallydispleasing, annoying installer and they also compromise installation.Since solutions are time consuming and costly. It serves no otherbenefits except for holding the curl down.

SUMMARY

Accordingly, the present invention was devised in light of the problemsdescribed above, to provide a dimensionally stable floor panelcomposition having a reinforced layer with a guide edge.

Therefore, there is a need to develop a way to overcome the edge peakingor curling not inherited from the product itself but from the complexenvironment of packaging and transportation. A floor panel is provided.The floor panel composition includes a wear layer and base layers. Thebase layer includes a first base sections having a first composition ofpolyvinyl chloride, filler, and plasticizer, a second base sectionshaving a second composition with a higher content of polyvinyl andplasticizer than the first composition, and a glass fiber sectionpositioned between the first base section and the second base section.Further, a protrusion is provided on one side the base layer andextending outward beyond the top layer.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be explained in greater detail with reference toembodiments, referring to the appended drawings, in which:

FIG. 1 is a top perspective view of a dimensionally stable floor panelaccording to the invention;

FIG. 2 is a bottom perspective view of the dimensionally stable floorpanel of FIG. 1;

FIG. 3 is a schematic diagram of the floor panel of FIG. 1, showinglayers thereof;

FIG. 4 is a sectional view of the floor panel of FIG. 1, taken alongline 4-4;

FIG. 5 is close-up view of portion 5 of the floor panel of FIG. 1;

FIG. 6 is a schematic diagram of adjacent floor panels according to theinvention; and

FIG. 7 is a schematic diagram of connecting adjacent floor panelsaccording to the invention;

DETAILED DESCRIPTION OF THE EMBODIMENT(S)

A surface covering relating to floor coverings, wallpapers, or othersurface coverings having a homogeneous, single layer, or aheterogeneous, multiple layer construction will now be discussed.Exemplary embodiments of the floor covering include Loose Lay LuxuryVinyl Tiles and Planks (“LLT”) as well as sheet flooring. However, oneof ordinary skill in the art would appreciate that the surface coveringmay also include other types of coverings, such as carpet backing, wallcoverings, semi-rigid extrusion sheet, vinyl underlayment, and resilienthard surface flooring such as vinyl composition tile, inlaid product aswell as cushion flooring.

Referring now to the drawings, in which like numerals refer to likeparts throughout the several views and embodiments.

In the embodiment shown in Figures, a single floor panel 1 is preparedfrom laminated polymeric components. Each floor panel 1 is prepared fromlaminated polymeric components, including vinyl, forming several layers.The total thickness of each floor panel, in the embodiments shown isapproximately 3.00-5.00 mm. However, it is also possible to prepare thefloor panel 1 having one or more layers, with each layer havingdiffering thickness. The composition of the floor panel 1 may vary aswell, with the floor panel 1 being prepared from various materials,including but not limited to polymers, ceramics, metals, organicmaterials, etc.

However, as illustrated in FIGS. 1-4, the floor panel 1 is prepared as alaminate having a top layer 10 of flexible polymeric sheet material, abase layer 20 of stabilized polymeric material, and a backing layer 30prepared from a non-slip polymeric material. Each of the layers 10, 20,and 30 has a different thickness, as shown. However, it is possible tohave layers of equal thicknesses. The thickness, layering, and overallfloor panel 1 preparation would accord to preferences of the finishedproduct, including dimensions. The manufacturing is not held to onespecific design, but rather incorporates the novel design featuresdescribed in the following paragraphs.

Furthermore, certain embodiments may include co-polymers, lubricants,fillers, pigments, or combinations thereof. The amounts of thecomposition components are expressed as parts per hundred on the weightof the polymer (“phr”).

According to the invention, the floor panel 1, which can be shaped aseither a square or rectangle, has four sides a, b, c, d, wherein eachside is connected by interior angles of 90° (right angles).Additionally, the floor panel 1 includes a top side 2 and a bottom side4. In the embodiment shown, the top side 2 is prepared from the toplayer 10 and the bottom side 4 is prepared using the backing layer 30.

As shown in FIGS. 1-4, the floor panel is prepared from various laminatecomponents. In the embodiment shown, the top layer 10 is prepared havingthree components: a thin coating layer 12, a durable wear layer 14 and aprint layer 16, with the print layer 16 having printed features. Any ofthe component pieces, such as the thin coating layer 12, the durablewear layer 14 or the print layer 16, may be textured in order to enhancefeatures of the floor panel 1 construction.

The thin coating layer 12 and the durable wear layer 14 are provided ontop of the print layer 16, and in the embodiment shown, the thin coatinglayer 12 and the durable wear layer 14 are transparent, being preparedfrom a plastic material having high durability.

In the embodiment shown, the print layer 16 is provided with a printedpattern, with the underside of the print layer 16 being bonded to thebase layer 20 and the printed pattern facing away from the backing layer30. The top layer 10 provides graphics and texture relief, and can beprepared to match any print or even mimic genuine metamorphic rockfeatures.

The thin coating layer 12, although not necessary, would be apolyurethane coating having a thickness around 0.03 mm. However, itwould be possible to vary the application, composition, and thickness ofthe thin coating layer 12 in regard to overall floor panel 1construction.

The top layer 10 further includes a transparent wear layer 14, in theembodiment shown. The wear layer 14 would be prepared from polyvinylchloride or other polymeric material, such as polypropylene. The wearlayer 14 is utilized to protect the print layer 16. And since the wearlayer 14 is transparent or clear, then any aesthetic print on the printlayer 16 would be visible through the wear layer 14. Although thethickness may vary, the wear layer 14 would range from 0.1-1.5 mm. Inthe shown embodiment, the wear layer 14 has a thickness around 0.50 mm.However, much like the coating layer 12, the application, composition,and thickness of the wear layer 14 may be prepared according to overallfloor panel 1 construction.

In an embodiment of the invention, the composition of wear layer 14includes a polyvinyl chloride and a plasticizer. It is preferred thatthe polyvinyl chloride have a K-value in the ranges of 60 to 70. Theplasticizer is preferred to be non-phthalate type plasticizers such asDOTP, DINCH and bio based plasticizer (i.e. Octadecanoic acid,10-chloro-9-methoxy-.methyl ester, etc.). The wear layer 14 may alsoinclude a stabilizer that is preferred to be a non-heavy metal contenttype stabilizer. For instance, a calcium/stearate and/or zinc stearateor calcium/zinc combined complex soap system may be used. Furthermore,the wear layer 14 may further include a co-stabilizer. For instance, anepoxidized soybean oil may be used. A lubricant may also be added to thewear layer, such as paraffin wax. Optionally, a UV stabilizer may alsobe added to the wear layer 14, which includes UV absorber and hinderamine to maximize the efficiency of UV stability.

Table 1 demonstrates an exemplary composition of the wear layer 14according to the invention.

TABLE 1 Ingredients Formula (phr) PVC 100 Plasticizer 18-32 HeatStabilizer 1.0-5.0 Co-stabilizer 0.5-3.0 Lubricant 0.1-1.5 UV Stabilizer0.1-1.5

The print layer 16 can be used to provide the floor panel 1 with printedgraphics, which would be used to enhance the aesthetics of the floorpanel 1. In the embodiment, the print layer 16 would be a decorativelayer having a printed design on a top surface of the print layer 16.The thickness of the print layer 16 can range from 0.07-0.1 mm. However,in an exemplary embodiment, the print layer 16 has a preferred thicknessaround 0.07 mm. Although the top layer 10 is positioned on top of thebase layer 20, the top layer 10 is transparent allowing any printedpattern on the top surface of the base layer 20 to be easily seen.

The print layer 16 can be printed by rotogravure printing, flexoprinting, digital printing or the transfer printing.

In an embodiment of the invention, the composition of print layer 16includes polyvinyl chloride and a plasticizer. In an embodiment of theinvention, the polyvinyl chloride has a K value in range of 60 to 70.The plasticizer is preferred to be non-phthalate type plasticizers suchas DOTP, DINCH and a bio based plasticizer (i.e. Octadecanoic acid,10-chloro-9-methoxy-.methyl ester, etc.). A stabilizer may be added tothe print layer 16 composition. Using a non-heavy metal content typestabilizer is preferred, such as calcium/stearate and/or zinc stearateor calcium/zinc combined complex soap system. The print layer 16 mayalso include a co-stabilizer. For instance, an epoxidized soybean oilmay be used. A titanium dioxide may also be added to the print layer 16in order to increase opacity.

Table 2 demonstrates an exemplary composition of the print layer 16according to the invention.

TABLE 2 Ingredients Formula (phr) PVC 100 Plasticizer  0-15 HeatStabilizer 1.0-5.0 Co-stabilizer 0.5-3.0 Titanium Dioxide 0.1-2.0

During manufacturing, the top layer 10, either solely the print layer 16or a combination of the thin coating layer 12, the durable wear layer14, and the print layer 16, may be prepared with textured features toenhance the feel of the floor panel 1. Therefore, if the top layer 10 isprepared with a printed pattern and a textured surface, the floor panel1 will have a presentation and feel of genuine wood, ceramic, ormetamorphic rock flooring.

If the print layer 16 is the top most layer of the floor panel, then theprint layer 16 should be prepared from material having higher resistantand resilient properties, than if the print layer 16 is prepared with atop wear layer 10.

According to the invention, the base layer 20 is prepared from variouspolyvinyl chloride layers. In the shown embodiment, the base layer 20includes an upper base section 22, an intermediate base section 24, alower base section 26, and a glass fiber section 28. In an exemplaryembodiment, the upper base section 22, the intermediate base section 24,and the lower base section 26 having differing compositions of polyvinylchloride and a filler.

In the shown embodiment, the base layer 20 is positioned between the toplayer 10 and the backing layer 30. The base layer 20 is the backbone ofthe construction, since it contributes greatly to the mechanicalproperties such as tear, gouge, indentation resistance, stiffness,flexibility etc. of the product, the cost, weight, dimensionalstability, flatness and many other properties. The number of the layersin the base layer 20 construction is dependent on the overall thicknessof the floor panel 1, including the thickness of the wear layer 14, thebalance of the construction, the formula of each layer, as well as theproduct cost etc.

The upper base section 22 is the layer directly underneath the printlayer 16 includes a composition of polyvinyl chloride and a filler.Other compositional elements may be provided, including plasticizers,stabilizers, pigments and a flame retardant.

The upper base section 22 has a higher amount of filler by parts per 100parts of polyvinyl chloride than the intermediate base section 24 andthe lower base section 26. As a result, the upper base section 22 willhave less polyvinyl chloride and plasticizer content than theintermediate base section 24 and the lower base section 26. In the shownembodiment, the upper base section 22 provides the rigidity and thehardness of the floor panel. Because of the high filler content and lesscontent in PVC and plasticizer, the thickness of the layer has asignificant impact on the cost of the overall product.

In the shown embodiment, the upper base section 22 includes polyvinylchloride, a primary plasticizer, a heat stabilizer, a co-heatstabilizer, a filler, a flame retardant, and a pigment. The plasticizeris preferred to be non-phthalate type plasticizers such as DOTP, DINCHand a bio based plasticizer (i.e. Octadecanoic acid,10-chloro-9-methoxy-.methyl ester, etc.). The upper base section 22 mayalso include a stabilizer, such as a non-heavy metal content typestabilizer. For instance, the non-heavy metal content type stabilizermay be calcium/stearate and/or zinc stearate or calcium/zinc combinedcomplex soap system. The upper base section 22 may also include aco-heat stabilizer, such as an epoxidized soybean oil. A filler may alsobe added in the upper base section 22. For instance, limestone may beused as a filler. A flame retardant, such as magnesium hydroxide, may beused. A pigment may also be added, such as carbon black or titaniumdioxide.

Table 3 demonstrates an exemplary composition of the upper base section22 according to the invention.

TABLE 3 Ingredients Formula (phr) PVC 100 Plasticizer 25-35 HeatStabilizer 2.0-5.0 Co-Heat Stabilizer 4.0-6.0 Filler 300-400 FlameRetardant 10-20 Pigment 0.3-1.0

In the shown embodiment, the upper base section 26 includes two layersof material that is then combined with the intermediate base section 24and lower base section 26 during manufacturing. However, one skilled inthe art should appreciate that other designs are possible, including thenumber of single layers making up the upper base section 22.

As shown in the Figures, the intermediate base section 24 is positionedbeneath the upper base section 22. According to the invention, theintermediate base section 24 has a composition similar to the upper basesection 22. However, that composition transitions from high fillercontent to low filler content, and subsequently higher polyvinylchloride content and plasticizer content. As a result, the intermediatebase section 24 according to the invention is well balanced in therigidity, flexibility, resiliency and many other mechanical properties.

In the shown embodiment, like the upper base section 22, theintermediate base section 24 includes polyvinyl chloride, a primaryplasticizer, a heat stabilizer, a co-heat stabilizer, a filler, a flameretardant, and a pigment. However, the composition is different as shownin Table 4 below.

In the shown embodiment, the intermediate base section 24 includespolyvinyl chloride, a primary plasticizer, a heat stabilizer, a co-heatstabilizer, a filler, a flame retardant, and a pigment. The plasticizeris preferred to be non-phthalate type plasticizers such as DOTP, DINCHand a bio based plasticizer (i.e. Octadecanoic acid,10-chloro-9-methoxy-.methyl ester, etc.). The intermediate base section24 may also include a stabilizer, such as a non-heavy metal content typestabilizer. For instance, the non-heavy metal content type stabilizermay be calcium/stearate and/or zinc stearate or calcium/zinc combinedcomplex soap system. The intermediate base section 24 may also include aco-heat stabilizer, such as an epoxidized soybean oil. A filler may alsobe added in the intermediate base section 24. For instance, limestonemay be used as a filler. A flame retardant, such as magnesium hydroxide,may be used. A pigment may also be added, such as carbon black ortitanium dioxide.

Table 4 demonstrates an exemplary composition of the intermediate basesection 24 according to the invention.

TABLE 4 Ingredients Formula (phr) PVC 100 Plasticizer 28-40 HeatStabilizer 2.0-5.0 Co-Heat Stabilizer 4.0-6.0 Filler 250-350 FlameRetardant 10-20 Pigment 0.3-1.0

In the shown embodiment, the intermediate base section 24 includes twoseparate material layers that are then combined with the upper basesection 22 and lower base section 26 during manufacturing, which isdescribed in more detail below. However, one skilled in the art shouldappreciate that other designs are possible, including the number ofsingle layers making up the lower base section 26.

As shown in the Figures, the lower base section 26 is positioned beneaththe intermediate base section 24. According to the invention, the lowerbase section 26 has a composition similar to the upper base section 22and the intermediate base section 24. However, as previously discussed,composition of the base layer 20 transitions from high filler content tolow filler content. This is performed through layering of the upper basesection 22, the intermediate base section 24, and the lower basesection. Subsequently, the upper base section 26 has higher polyvinylchloride content and plasticizer content than the upper base section 22,the intermediate base section 24.

The lower base section 26 has the most polyvinyl chloride andplasticizer. The overall content polyvinyl chloride and plasticizer inthe lower base section depends upon the thickness of the durable wearlayer 14. A thick durable wear layer 14 is required for higher amountsof the PVC and plasticizer content in the lower base section 26 in orderto get the proper balance of the construction and maintain properflatness, dimensional stability.

In the shown embodiment, like the upper base section 22 and theintermediate base section 24, the lower base section 26 includespolyvinyl chloride, a primary plasticizer, a heat stabilizer, a co-heatstabilizer, a filler, a flame retardant, and a pigment. However, thecomposition is different as shown in Table 5 below.

In the shown embodiment, the lower base section 26 includes polyvinylchloride, a primary plasticizer, a heat stabilizer, a co-heatstabilizer, a filler, a flame retardant, and a pigment. The plasticizeris preferred to be non-phthalate type plasticizers such as DOTP, DINCHand a bio based plasticizer (i.e. Octadecanoic acid,10-chloro-9-methoxy-.methyl ester, etc.). The lower base section 26 mayalso include a stabilizer, such as a non-heavy metal content typestabilizer. For instance, the non-heavy metal content type stabilizermay be calcium/stearate and/or zinc stearate or calcium/zinc combinedcomplex soap system. The lower base section 26 may also include aco-heat stabilizer, such as an epoxidized soybean oil. A filler may alsobe added in the lower base section 26. For instance, limestone may beused as a filler. A flame retardant, such as magnesium hydroxide, may beused. A pigment may also be added, such as carbon black or titaniumdioxide.

Table 5 demonstrates an exemplary composition of the lower base section26 according to the invention.

TABLE 5 Ingredients Formula (phr) PVC 100 Plasticizer 35-55 HeatStabilizer 2.0-5.0 Co-Heat Stabilizer 4.0-6.0 Filler 200-300 FlameRetardant 10-20 Pigment 0.3-1.0

In the shown embodiment, the lower base section 26 includes a singlelayer of material that is then combined with the upper base section 22and intermediate base section 24 during manufacturing, which isdescribed in more detail below. However, one skilled in the art shouldappreciate that other designs are possible, including the multiplelayers making up the lower base section 26. As shown in FIG. 4, thelower base section 26 may be milled or embossed to form a pattern on thebottom of the base layer 20.

According to the invention, the base layer 20 includes a glass fibersection 28 which is added within the base section for rigidity. In theshown embodiment, the glass fiber section 28 is positioned between theupper base section 22 and the intermediate base section to control theexpansion and contraction of the panel 1.

In an exemplary embodiment of the invention, the glass fiber section 28is a veil of glass fibers in the ranges of 10 gram/m2 to 25 gram/m2 thatare coated with polyvinyl plastisol. The polyvinyl plastisol is added sothat the glass fiber section 28 bonds with the other sections of thebase layer 20.

The overall thickness of the base layer 20 may vary. However, in theembodiment shown, the base layer 20 is prepared having a thicknessranging from 2.8 mm-4.7 mm.

As shown in FIGS. 3 and 4, the backing layer 30, which is optional aswell, is prepared from a single layer of non-slip plastic. The backinglayer 30 functions as a non-slip backing layer. Additionally, thebacking layer 30 may be provided to balance the top layer 10,essentially averting warping of the floor panel 1. Although the backinglayer 30 thicknesses may vary, it is appropriate to provide the backinglayer 30 having a thickness ranging from 0.2-1.0 mm, and in anembodiment of the invention the backing layer 30 has a thickness 0.2-0.3mm. The backing layer 30 could be prepared from a variety of materials,including but not limited to polyvinyl chloride, polypropylene,polyolefin, etc. The composition would depend on the intendedapplication of the floor panel 1.

In the shown embodiment, the backing layer 30 is attached to the lowerbase section 26 and makes up a bottom of the floor panel 1 in order tostabilize the floor panel 1 from the movement when the floor panel isinstalled. An embossed texture pattern is created to further enhance itsnon-slip performance of the floor panel 1. Either the backing layer 30can be embossed or the base layer 20 can be embossed, and the backinglayer 30 is then formed over the embossed base layer 20, as shown.

In an exemplary embodiment of the invention, the backing layer 30 has acomposition of polyvinyl chloride and a plasticizer. Therefore, thebacking layer 30 is rather pliable and adaptable to subfloorirregularity.

As shown in FIGS. 5-7, the floor panel includes tongue and grooveconnection sections 50, 60. The tongue and groove connection sections50, 60 can be prepared in various shapes, i.e. although the basic shapeshould include a slot (the groove connection section 60) cut all alongone side of the floor panel 1, and a protrusion (the tongue connectionsection 50) on the opposite side of the floor panel. The tongueconnection section 50 should project a little less than the grooveconnection section 60 is prepared deep.

The tongue connection section 50 is a protrusion prepared on one sideand extending longer beyond the top layer 10 of the floor panel 1. Asbest shown in FIG. 5, the tongue connection section 50 has a first guideelement 52, which is formed on the lower section of the tongueconnection section 50. The first guide element 52 is round shaped havinga surface length longer than a top surface 53 of the tongue. Therefore,the first guide element 52 extends into the body of an adjacent floorpanel 1, as shown in FIG. 7. The top surface 53 and the tongue end 54should be shaped to have a flat surface 56 and tapered surface 58 topromote airflow when connecting adjacent floor panels.

The groove connection section 60 is formed on an opposite side to thetongue connection section 50. However, the groove connection section 60extends beyond the peripheral edge of the top layer 10 of the floorpanel 1. A second guide element 62, is formed by the recess and having adownwardly concave shape. The dimensions of both the first guide element52 and the second guide element 62 should be approximately the same inboth radii and length. The groove connection section 60 also includes anupper inclined wall 64 and an inner wall 66.

The tongue connection section 50 and the groove connection section 60are formed having complimentary shapes, so that when the tongueconnection section 50 engages the groove connection section 60 ofanother floor panel 1, the top surface 53, tongue end 54, and firstguide element 52 sit against the upper inclined wall 64, inner wall 66and second guide element 62 respectively. Since the guide elements 52,62 have a curve shape, connecting floor panels cannot be pulled apart inthe horizontal direction.

Importantly, the tongue connection section 50 and the groove connectionsection 60 are formed in the base layer 20. In an exemplary embodiment,the tongue connection section 50 is formed by the glass fiber section 28and the intermediate base section 24. However, one skilled in the artshould appreciate that the tongue connection section 50 can be formed inother section of the base layer 20.

Now, an exemplary procedure for manufacturing the floor panel 1 will bedescribed.

The wear layer 14 is prepared using an extrusion process and asubsequent four roll calendaring process. The wear layer may include apolyvinyl powder, a plasticizer, a stabilizer, a co-stabilizer, alubricant, and a UV light stabilizer as needed per formulation. Thesecomponents are added together and then mixed uniformly in a low shearmixer. The mixture is then fed to a kneader extruder, which includes ascrew conveyor built into the mixing chamber. The screw revolvescontinuously away from the discharge end and moves the material into thereach of the mixing arm, and then extruded out of the mixing chamber toform a rope-like extrudate. The extrudate is then fed into a planetaryextruder. The planetary system may consist of one hollow barrel and amain spindle (screw), as well as several satellite screws (spindles),which synchronize harmoniously with each other to enable satisfactorymixing and plastification. The extrudate material is then furtherprocessed into a melt through a softer hot melt stage. The melt is thenworked through a calender roll mill heated to a similar temperature. Theshear mixing action on the surface of the calender rollers fluxes themelt and forms a polymer sheet having a controlled thickness. Thethickness of the polymer sheet is controlled by adjusting the distancebetween the calendar rolls. The sheets are then cooled and collected ona reel or cut into sheets depending upon the equipment and the processof the downstream operation. For the continuous lamination operation,the sheet is produced as a roll form and then cut into a size that fitsto the size of the hot press.

Next, the base layer 20 is prepared wherein each layer of the upper,middle and lower base sections 22, 24, 26 are prepared separately. Forthe sake of brevity, only the preparation of the upper base section 22will be described. However, one skilled in the art would appreciate thatthe same process can be performed with the intermediate base section 24and the lower base section 26 with different composition ratios, asdiscussed above.

First, with respect to the upper base section 22, the polyvinylchloride, stabilizer and pigments are added together and then uniformlyhot mixed using a shear mixer. The rest of the compositional elements,such as the filler and fire retardant, is feed into the mixture and thenfed into kneader extruder and limestone is uniformly mixed in. The mixedcomposition is then fed into banbury mixer that includes two mixingrotors mounted for rotation in a mixing chamber, as well as a rammounted for sliding the mixed compound through a passage opening intothe mixing chamber. The mixed material is then discharged when targettemperatures over time are achieved. At this stage, the dischargedmaterial is at a temperature of 150-215° C. in a hot melt form. The meltis then worked through a calender roll mill and heated to a similartemperature. The shear mixing action on the surface of the calenderrollers fluxes the melt and forms a polymer sheet having a controlledthickness. The thickness of the upper base section 22 is controlled byadjusting the distance between the calendar rolls. The sheets are thencooled and collected on a reel or cut into sheets.

A typical procedure for the manufacture of an LVT involves laminatingthe base layer 20. The laminate is compressed under heat and pressure.In an embodiment of the invention, the lamination is a continuouslamination.

In an exemplary embodiment, the LVT may be prepared by laminatingtogether the following sequence:

(1) one or more layer of the lower base section 26;

(2) the glass fiber section 28;

(3) one or more layers of the intermediate base section 24; and

(4) one or more layers of the upper base section 22;

The laminated sections of the base layer 20 is then cut into slabs. Forinstance, the laminated base layer 20 may be cut into 1 m×1 m slabs.

At this time, the lower base section 26 may be milled or embossed toform a pattern on the bottom of the base layer 20.

A typical procedure for the manufacture of an LVT involves hot pressingthe base layer 20 and the top layer 10. The laminate is compressed underheat and pressure. In an embodiment of the invention, the lamination isa continuous lamination.

In an exemplary embodiment, the LVT is then prepared by hot pressing thelaminated base layer 20 with the backing layer 30 and the top layer 10together in the following sequence:

(1) the wear layer 14;

(2) the print layer 16;

(3) the base layer 20; and

(4) the backing layer 30.

An embossing plate is placed on top of the above assembled stack. Thestack is then heated to approximately 130° C.-150 o C and approximately3-5 MPa of pressure is applied through the embossing plate for about20-30 minutes. The press is then cooled to 30°-50° C. and the LVT isremoved.

Furthermore, the floor panel 1 is then cooled down for few hours andthen an Ultraviolet curable coating system is applied on a surface ofproduct to form the thin coating layer 12. The coating material istypically formulated with urethane acrylates oligomer with functionalmonomer and photo initiator and others that under appropriate UV energyto cure the coating and form a hard three dimensional crosslink surface.The UV coating provides an excellent surface properties for the flooringsuch as stain and chemical resistance, appearance & gloss retention,scratch and abrasive resistance etc.

After coating, the product is further processed through annealing inorder to release the internal stress from the previous processes.Without proper annealing, the dimensional stability of the product maybe compromised. Further processes may follow annealing, such asacclamation, punching, profiling to form tongue and groove lockingprofile, and inspection before packaging into cartons, among others wellknown in the industry.

The foregoing illustrates some of the possibilities for practicing theinvention. Many other embodiments and fields of use for an LVT to theinvention are possible and within the scope and spirit of the invention.It is, therefore, intended that the foregoing description be regarded asillustrative rather than limiting, and that the scope of the inventionis given by the appended claims together with their full range ofequivalents.

What is claimed is:
 1. A floor panel composition comprising: a toplayer; a base layer having: a first base section with a firstcomposition of polyvinyl chloride, a filler, and a plasticizer; a secondbase section having a second composition with a higher content ofpolyvinyl and plasticizer than the first composition of polyvinylchloride, filler, and plasticizer; and a glass fiber section positionedbetween the first base section and the second base section.
 2. The floorpanel of claim 1, further comprising a protrusion prepared on one sidethe base layer and extending outward beyond the top layer.
 3. The floorpanel of claim 2, wherein the filler of the first base section being300-400 parts per 100 parts of the polyvinyl chloride.
 4. The floorpanel of claim 3, wherein the plasticizer of the first base sectionbeing 25-35 parts per 100 parts of the polyvinyl chloride.
 5. The floorpanel of claim 4, wherein the first base section further includes a heatstabilizer being 2.0-5.0 parts per 100 parts of the polyvinyl chloride.6. The floor panel of claim 5, wherein the first base section furtherincludes a co-heat stabilizer being 4.0-6.0 parts per 100 parts of thepolyvinyl chloride.
 7. The floor panel of claim 6, wherein the firstbase section further includes a flame retardant being 10.0-20.0 partsper 100 parts of the polyvinyl chloride.
 8. The floor panel of claim 7,wherein the first base section further includes a pigment being 0.3-1.0parts per 100 parts of the polyvinyl chloride.
 9. The floor panel ofclaim 4, wherein the filler of the second base section being 250-350parts per 100 parts of the polyvinyl chloride.
 10. The floor panel ofclaim 9, wherein the plasticizer of the second base section being 28-40parts per 100 parts of the polyvinyl chloride.
 11. The floor panel ofclaim 10, wherein the second base section further includes a heatstabilizer being 2.0-5.0 parts per 100 parts of the polyvinyl chloride.12. The floor panel of claim 11, wherein the second base section furtherincludes a co-heat stabilizer being 4.0-6.0 parts per 100 parts of thepolyvinyl chloride.
 13. The floor panel of claim 12, wherein the secondbase section further includes a flame retardant being 10.0-20.0 partsper 100 parts of the polyvinyl chloride.
 14. The floor panel of claim13, wherein the second base section further includes a pigment being0.3-1.0 parts per 100 parts of the polyvinyl chloride.
 15. The floorpanel of claim 10, further comprising a third base section positionedalong the second base section and having polyvinyl chloride and a fillerbeing 200-300 parts per 100 parts of the polyvinyl chloride.
 16. Thefloor panel of claim 15, wherein the third second base section furtherincludes a plasticizer being 35-55 parts per 100 parts of the polyvinylchloride.
 17. The floor panel of claim 16, wherein the third basesection further includes a heat stabilizer being 2.0-5.0 parts per 100parts of the polyvinyl chloride.
 18. The floor panel of claim 17,wherein the third base section further includes a co-heat stabilizerbeing 4.0-6.0 parts per 100 parts of the polyvinyl chloride.
 19. Thefloor panel of claim 18, wherein the third base section further includesa flame retardant being 10.0-20.0 parts per 100 parts of the polyvinylchloride.
 20. The floor panel of claim 19, wherein the third basesection further includes a pigment being 0.3-1.0 parts per 100 parts ofthe polyvinyl chloride.
 21. The floor panel of claim 1, wherein theglass fiber section is a veil of glass fibers in the ranges of 10gram/m2 to 25 gram/m2 and are coated with polyvinyl plastisol.
 22. Afloor panel composition comprising: a first base section having: a firstpolymer; a first filler being 300-400 parts per 100 parts of the firstpolymer a first plasticizer being 25-35 parts per 100 parts of the firstpolymer. a second base section having: a second polymer; a second fillerbeing 250-350 parts per 100 parts of the second polymer a secondplasticizer being 28-40 parts per 100 parts of the second polymer; and aglass fiber section positioned between the first base section and thesecond base section; and a protrusion prepared from the second basesection and extending out ward from the first base section.
 23. Thefloor panel of claim 22, further comprising a third base sectionpositioned along the second base section and having polyvinyl chlorideand a filler being 200-300 parts per 100 parts of the polyvinylchloride.
 24. The floor panel of claim 23, wherein the third second basesection further includes a plasticizer being 35-55 parts per 100 partsof the polyvinyl chloride.
 25. The floor panel of claim 24, wherein thethird base section further includes a heat stabilizer being 2.0-5.0parts per 100 parts of the polyvinyl chloride.
 26. The floor panel ofclaim 25, wherein the third base section further includes a co-heatstabilizer being 4.0-6.0 parts per 100 parts of the polyvinyl chloride.27. The floor panel of claim 26, wherein the third base section furtherincludes a flame retardant being 10.0-20.0 parts per 100 parts of thepolyvinyl chloride.
 28. The floor panel of claim 27, wherein the thirdbase section further includes a pigment being 0.3-1.0 parts per 100parts of the polyvinyl chloride.
 29. The floor panel of claim 22,wherein the glass fiber section is a veil of glass fibers in the rangesof 10 gram/m2 to 25 gram/m2 and are coated with polyvinyl plastisol.